Technical English

CPA
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FETHIL INDUSTRIAL MACHINES Hydraulic Presses HSP Metal Drawing Press HSP-D D Form Deep Drawing Press
Model Platen dimensions mm Max# da$light mm %amstro&e mm 'lamping (orce MP *pproach speed mm+sec ,or&ing speed mm+sec Force o( -lan& holder MP Stro&e o( -lan& holder MP .perating press/re &p+cm) Motor power 0P 1ase dimensions mm Total high a-o3e (loor mm HSP 80/30 450x515 550 !00 "0 100 1! !0 )00 )50 15 200x1100 !000 HSP 120/40 !5x"00 "00 400 1)0 150 10 40 )00 !00 )0 1000x1)00 !)50 HSP 150/50 !5x"00 "00 400 150 150 11 50 )00 !00 )5 1000x1)00 4000 HSP 250/80 "00x"00 1000 550 )50 100 1)#5 "0 )00 !00 40 1)00x1400 4)00 HSP 300/100 "00x"00 1000 00 !00 100 15 100 )50 !00 50 1)00x1400 4500

Factor$ 4a$o/t

%o-lan Plastic Mo/lding Di3ision is an */stralian Man/(act/rer#,e o((er relia-le ser3ice to all ind/stries# ,e can pro3ide 5n6ection to 500 tonne capacit$# Most t$pes o( materials processed7 Thermoplastics - Pol$prop$lene8 Pol$eth$lene 9 most engineering plastics# Engel 0 9 100 Tonne 5n6ecting Machines Engel 110 Tonne Machine Engel 125 Tonne 5n6ection Plant Engel )50 Tonne 5n6ection Plant Engel 400 Tonne 5n6ection Plant The (loor o( the 4eichhardt Mo/lding Plant

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Technical English

CPA
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:o/ can rel$ on o/r Quality Control to $o/r speci(ications8 (rom tool design to the (inished prod/ct### %o-lan;s Plastic Mo/lding Di3ision is located at 4eichhardt8 inner-west o( S$dne$# 4as<lo Mag$ar is Director o( %o-lan;s Plastic Mo/lding Di3ision 5an Dowling is Prod/ction Manager# Welcome to Drame ! "anded metal Drame Cor"oration was (o/nded in 1=5" and has grown to -ecome the largest and most modern man/(act/rer o( expanded metal prod/cts in >orth *merica# Expanded Metal is o/r onl$ -/siness# ./r team o( specialists o((er prod/ct training8 engineering and technical s/pport which is second to none# Dramex can help $o/ with sol/tions to $o/r needs# '/stomer ser3ice remains the &e$ to o/r s/ccess# Dramex has six man/(act/ring and two distri-/tion locations to deli3er prod/ct (ast8 e((icientl$ and on time# Dramex e?/ipment is state-o(-the-art# Prod/ction (rom coil or a/tomated sheet (eeding s$stems allow the comp/ter operated expanding presses to r/n at high speeds prod/cing ?/alit$ prod/ct /nto/ched -$ the rest o( the ind/str$# Contact Drame (or all $o/r expanded metal needs and -e ass/red $o/ made the right choice@ #o$lan%s &n'le$urn Premises ./r 5ngle-/rn plant has -een the centre o( the compan$;s Metal Pressing Di3ision since 1=="# 5t was relocated (rom 4eichhardt8 to allow (or expansion o( the Mo/lding Di3ision8 which incl/ded the installation o( a Trans(er Press 4ine o( (o/r ) 0 tonne presses 1ronw$n Mac&awa$ ,a$ne :o/nie Aim Macdonald %eceptionist+Sales Pressing Di3ision Manager Di3isional Sales Manager 'ler& will control all $o/r Prod/ction will -e happ$ to help $o/ with new 5ngle-/rn re?/irements Metal Pressing en?/iries# Started in Ma$ )001 #o$lan Metal Pressin' Di(ision is an )ustralian Manu*acturer+ We o**er relia$le ser(ice to all industries We can "ro(ide Metal Pressin', to 2-0 tonne ca"acity+++ .ou can rely on our Quality Control to your s"eci*ications+++ *rom tool desi'n to t/e *inis/ed "roduct+++

0)12)3D%S 4)C50#. 2).065

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Technical English

CPA
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Detailed Machine 4ists

Plastic Mac/inery 8rou" */tomatic c/tting and welding machines 1o--in '/tting Machine 'omplete Electrical 'a-le 4ines Plastic -ag ma&ing and &nitting Machines Plastic 1ag c/tting Machines Plastic -all and -alloon Machines Plastic 1low Molding Machines Plastic 'r/sher - Mill Machines Plastic Extr/der Machines (or pipes8 pro(iles and ca-les Plastic Film Machines PP + HDPE + 4DPE Model 1 9 Model ) Plastic Film Flexo Printing Machines Plastic 5n6ection Molding Machine Plastic 5n6ection 1low Mo/lding Machines Plastic mo/lds Plastic Pipe Prod/ction 4ines Plastic Pro(ile Prod/ction 4ines Plastic PB' Mixer Machine Model 1 9 Model ) Plastic Shoe sole in6ection Machines PP 1r/sh Prod/ction 4ine PB' Cran/le Machine Plastic Pipe Fittings ,elding Machine Sponge prod/ction line Thermo(orm plastic sheet and molding Machines Metal Mac/inery 8rou" */tomate Tools 'a-le end '/tting Machine '/tter Crinding Machines Decoiler Machines (or Metal sheets8 motor powered Eccentric presses Electro erosion Machines Friction Presses Class mo/lds (or all a/tomatic Machines and Man/el Man/(act/ring Cold Aewelr$ Processing Machines Cold Molds H$dra/lic press -ra&es H$dra/lic and mechanical g/illotine shears H$dra/lic Presses 5nd/strial springs8 red/cers and motors8 sensiti3e part E'>' prod/ctsF Aewelr$ Processing Machines Mar-le processing8 c/tting and polishing Machines Metal al/min/m in6ection Machines Metal 1and Saw '/tting Machines Metal c/tting8 -ending8 deep drawing dies 9 casting Mo/lds >ail prod/ction machine Painting a/tomatic and man/al ca-ins and enameled o3ens Per(ore Metal Sheet Hole P/ncing Machine Pne/matic Feeding Dnits %olling Machines Terminal 'a-le 'lips Machine - Press Trans(er Machines Dni3ersal Engra3ing *nd 'op$ Milling Machine Dni3ersal S/r(ace Engra3ing Machine Dni3ersal Tool Crinder Machine Pac7in' Mac/inery 8rou" */tomatic Per(/me Filling and 'aping Machine */tomatic *erosol Filling and 'rimping Machine 1listerpac& Machine '/p Filling Machine Filling 4a-eling 'apping Machine Flow Pac& Pac&ing Machine 4a-eling Machines .3erwrapping Pac&ing Machine Paper 1ag Filling Machine %otati3e Ta-let Machine Shrin& Pac&ing Machine Thermo(orm Pac&ing Machine Bertical Pac&ing Machine Bol/metric 4i?/id and Solid Filling Machines ,et-wipes F/ll */tomatic 4ine &ndustrial S"are Parts 1roaching Tools8 %olling Dies8 Taps8 Thread rolling dies Electrical 'omponents Electrical F/se and -ases -ase Electrical rotar$ 'am Switches Class Molds H$dra/lic 'omponents H$dra/lic (low-control8 loc& t$pe and speed control t$pe 3al3es H$dra/lic c$linders H$dra/lic gear P/mps Material Handling S$stems 'on3e$ors Pne/matic 'omponents Pne/matic Filters8 reg/lators8 4/-ricators Pne/matic Man/all$ and (oot operated 3al3es Pne/matic Solenoid 3al3es8 *ir operated 3al3es8 Mechanicall$ operated 3al3es Pne/matic */xiliar$ components Pne/matic c$linders and accessories %edactors8 motor-powered Bal3es 1/tter(l$8 glo-e8 chec&8 controlled chec&8 swing chec&8 strainer 3al3es 1all 3al3e (/ll and red/ced -ore Cate 3al3es 0t/er Mac/ines 9 Hea(y &ndustries Pac&aged T$pe *ir 'onditioners8 Panel T$pe 'limate Dnits ,ater 'ooling Towers8 with radial (an 'old generator8 Pac&aged t$pe cold water prod/cer Hea3$ 5nd/str$ Machines Soap Man/(act/ring complete lines

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CPA
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Training

the PD%5T: *DT. case - one possi-le sol/tion The sol/tion act/all$ adopted Enot necessaril$ the -est nor the onl$ oneF was -ased on health$ principles o( 2ean Manu*acturin'/4lo: Production and Cell Manu*acturin' The -asic targets were7 - drastic red/ction o( stoc&8 especiall$ (inished prod/ct - red/ction o( red/ndant manpower - rationalisation o( la$o/t - Gp/llG prod/ction8 as m/ch as possi-le - maintaining or -ettering the present Gresponsi3enessG to c/stomers; expectations Edeli3er$ timeF - elimination o( the present ?/alit$ pro-lems Ewrong deli3eriesF 5nitial st/dies were carried o/t# *ll Gc$cle timesG were acc/ratel$ meas/red# * (ew concl/sions came o/t crisp and clear7

The s/m o( the o3erall (alue addin' time Etime d/ring which 3al/e was act/all$ added to the prod/ctF correspondent to one $ear o( prod/ction Eapprox# )#000#000 sachets pac&aged and cartonisedF was considera-l$ less than one-$ear normal wor&ing time o( two la-o/rers# 4i&e to sa$ that two la-o/rers8 wor&ing onl$ to Gadd 3al/eG8 wo/ld 3er$ well cope with the present le3el o( demanded prod/ction# This ga3e immediatel$ an idea o( the presentl$ GwastedG la-o/r# 5t was also easil$ concl/ded that the present waste was hiding in the handling8 do/-le-handling8 mo3ing8 storing8 par&ing8 searching8 etc# o( ,5P Ewor& in progressF and (inished prod/ct# This was ca/sed -$ the present $atc/ "roduction met/od totall$ "us/ in its st$le# There(ore8 -$ switching o3er to a di((erent method E"ull and *lo:F most pro-a-l$ the present waste wo/ld -e exposed to light and eliminated#

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Technical English

CPA
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Training

o o

Howe3er8 it was clear that a "ull method wo/ld -e eas$ to implement8 starting (rom downstream8 (or the entire pac&aging process - -/t with the exception o( the Sachets (illing operations# D/e to the complexit$ o( changing o3er too o(ten (rom one (ragrance (illing to another8 it was concl/ded that the optimal method o( Sachets (illing wo/ld ha3e still to -e "us/ in st$le8 -ased on -atches e?/i3alent at least to one (/ll dr/m o( gran/les per (ragrance E4000 sachets o( a (ragrance - approx# hal( da$ prod/ction in one machineF# 5n an$ case8 tho/gh maintaining a G-atchG sachets (illing method8 it was concl/ded that one la-o/rer wo/ld -e capa-le o( prod/cing with one machine "000 (illed sachets+da$ E) (/ll dr/msF8 e?/i3alent to 1#=! #000 sachets per $ear E"000 sachets per da$ x )) da$s+month x 11 months+$earF8 witho/t o3ertime# 5t was also concl/ded that another la-o/rer wo/ld ha3e ample time to pac&age all (inished prod/cts8 pro3ided her acti3ities wo/ld -e mainl$ (alue addin' in their nat/re# This wo/ld impl$ to c/t to nil all c/rrent waste(/l acti3ities Eas descri-ed a-o3eF# The onl$ answer was to organise wor&ing areas dedicated to the entire pac&aging process8 starting (rom F/ll Sachets and Pac&aging Materials8 and ending /p8 in one c$cle8 with (inished prod/cts#

The entire process was re-engineered8 and the (actor$ la$o/t re-designed accordingl$# 5t was easil$ concl/ded that it wo/ld -e worthwhile to in3est in some extra e?/ipment Esimple8 home-made-st$le pac&aging and deli3er$ (acilitiesF8 -earing in mind the corresponding la-o/r sa3ings#

There was a snag8 tho/gh# Since the target was to manage the entire operations with the ) permanentl$ emplo$ed la-o/rers8 it was 3er$ important to ma&e -oth o( them m/lti-s&ill+m/lti-(/nction and (/ll$ interchangea-le E(or a n/m-er o( good reasonsF# So -oth o( them had to -e grad/all$ re-trained in the new st$le operations Eas (/ll$ descri-ed -elowF8 and -oth o( them were deepl$ in3ol3ed in the re-engineering process# The (inal o/tcome Egrad/all$ implemented in a-o/t 4 monthsF8 was as (ollows7

o 2a$our or'anisation# The two la-o/rers were exchanging roles on a wee&l$ -asis7 d/ring a certain wee& the
one wo/ld onl$ do Sachets (illing operating one machine8 while the other la-o/rer wo/ld do all the rest E(inal pac&aging o( all prod/cts - ta&ing orders - preparing orders - attending to prod/cts deli3er$ - (actor$ logistics and cleaning - and helping8 occasionall$8 with Sachets (illing at the second machineF - d/ring the (ollowing wee& the$ wo/ld simpl$ exchange their roles# This was done in order to mitigate the -oredom associated with ro/tine Sachets (illing wor&# Sac/ets 4illin'# This was done on a p/re "us/ -asis# The simple method was to maintain a predetermined F/ll Sachets stoc& le3el8 -ased on past sales statistics# 0rders 5a7in'# This was done -$ the G'ler&G o( the wee& Ethe la-o/rer in charge o( pac&aging8 orders ta&ing8 etc# (or that wee&F# Since the -/l& o( her time wo/ld -e spent in the (actor$ - rather than in the o((ice - she was pro3ided with a wireless phone that she co/ld carr$ aro/nd in the (actor$# So that8 where3er she was8 she co/ld easil$ ta&e orders and record them in a simple &nternal 0rder (orm# 0rders Processin'# This was also done -$ the G'ler&G o( the wee&# Processing was done thro/gh an extremel$ simple comp/ter program E-ased on a spreadsheetF7 *ll orders recei3ed -etween 0"700 and 1)700 wo/ld -e processed 6/st a(ter l/nch time E1)700 - 1)7!0F8 i#e# in the a(ternoon# *ll orders recei3ed -etween 1)7!0 and 1 7!0 wo/ld -e processed (irst thing next da$# The 'ler& wo/ld inp/t all orders details in the spreadsheet program# * progressi3e &nternal 0rder 3um$er wo/ld -e assigned /ni?/el$ to each order#

o o

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Technical English

CPA
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Training

o The comp/terised program wo/ld then a/tomaticall$ print all sel(-adhesi3e la$els to -e st/c& onto each
'arton -elonging to that order# The la-el wo/ld indicate7 5nternal .rder n/m-er - Deli3er$ >ote n/m-er - '/stomer >ame and F/ll *ddress - '/stomer .rder >/m-er Ei( an$F 'arton content Ei#e# 1 assorted Displa$ 1ox - 50 sachets 4a3ender - etc#F - 'arton o( y# o The program wo/ld also print a/tomaticall$ the Deli(ery 3ote E) copiesF associated with each .rder# o The program wo/ld also print a Deli(ery ;in Stic7er Esee -elowF o 0rders Pre"aration# *(ter processing a -atch o( orders8 the 'ler& wo/ld immediatel$ get read$ (or (inal pac&aging o( those orders# Deli(ery ;ins and a Deli(ery Counter were essential items o( the re-engineering exercise# The 'ler& wo/ld get a n/m-er o( plastic Deli(ery ;ins e?/i3alent to the n/m-er o( orders to -e pac&aged# She wo/ld stic& the Deli(ery ;in Stic7er onto each 1in# 5nsert in the 1in the ) copies o( the Deli(ery 3ote# *nd -ring each .rder 1in to the special Pac&aging 'ell dedicated to that t$pe o( prod/ct

o Then the 'ler& wo/ld -ecome a Pac&aging 4a-o/rer and start pac&aging each order# o Pac&aging wo/ld -e carried o/t in dedicated Pac7a'in' Cells# There were two (or Displa$ 1oxes8 one (or
'artons o( 1lister Pac&s8 and one (or 'artons o( 50+)00 Sachets#

Esee -elowF#

o Pac7a'in' o* Dis"lay ;o es#

The Displa$ 1oxes Pac&aging 'ell contains all what is re?/ired to assem-le and cartonise Displa$ 1oxes Ewith assorted-(ragrances or one-(ragrance pac&sF7 (/ll sachets - empt$ pac&s - instr/ction lea(lets - empt$ displa$ -oxes8 etc# The la-o/rer wor&s cloc&wise# First she opens /p a (lat8 empt$ Displa$ 1ox - then she starts pac&aging pac&s8 and inserts them straight awa$ in the Displa$ 1ox - once the Displa$ 1ox is (/ll8 she closes it8 and she cartonises it straight awa$ - the carton is sealed with tape Eergonomicall$ positioned in a dispenserF - then the 'arton 4a-el is st/c& onto it - the 'arton goes immediatel$ into the Deli3er$ 1in# This means that all acti3ities carried o/t -$ the 4a-o/rer are (alue addin' acti3ities# Practicall$ Eexcept some micro in-acti3ities or some positioning micro-acti3itiesF there is no wasted time# The 'ell o/tp/t is a (inished prod/ct8 read$ to -e dispatched# The 'ell la$o/t is 3er$ rational7 all GcomponentsG are stoc&ed in logical se?/ence8 so that wor& is a contin/o/s (low o( 3al/e adding mo3ements# The GcontainersG o( all components are slightl$ inclined (orward8 so that items are

easier to reach and gra- Egra3it$ does the tric&F# 5t is interesting to note the s$stem that was /sed to Gpar&G 'artons 4a-els -elonging to the same c/stomer order# Since 4a-els were printed in strips Eone strip per order - there(ore8 a minim/m o( two la-els in a stripF8

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Technical English

CPA
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Training

a Grac&G was made and placed on a stand in the 'ell wor&-ench to hang the 3ario/s strips8 so that each order to -e processed in the same 'ell wo/ld not -e mixed /p# Strips also made easier and (aster pic&ing /p and stic&ing la-els onto cartons# Empt$ strips E H order completedF wo/ld -e disposed o( thro/gh a disposal hole in the wor&-ench8 and 3ia a ch/te the$ wo/ld (all straight into a d/st-in# The 'ell st$le o( pac&aging impro3ed drasticall$ the o3erall '$cle Time# The G-e(oreG '$cle Time was7 approx# 5 seconds per pac& H 1)0 seconds (or )4 pac&s - -etween )5 ad !5 seconds to (ill a Displa$ 1ox Edepending7 one (ragrance or assorted (ragrancesF - and approx# )0 seconds to cartonise the Displa$ 1ox# 5n total8 it was -etween 1 5 and 125 seconds (or the entire operation Ecarried o/t in G(ragmentsG and at di((erent timesF# The Ga(terG '$cle Time showed constant impro3ement o3er time E/ntil the 4a-o/rers (amiliarised with the 'ell st$leF# E3ent/all$8 it sta-ilised at 6/st less than ) min/tes8 -oth (or assorted-(ragrances and one-(ragrance Displa$ 1oxes8 with a net impro3ement o( !5I Et$pical8 when switching o3er (rom ;atc/ to 4lo:/CellF# o Pre"aration *or Deli(ery ,hen each c/stomer order was completed8 the 'ler&+Pac&aging 4a-o/rer wo/ld place immediatel$ the corresponding Deli(ery ;in onto the Deli(ery Counter -e(ore proceeding with pac&aging the next c/stomer order# This was a r/le8 which wor&ed o/t extremel$ well7 no more mixing-/p o( orders too& place an$ longer# So8 the in3estment in a lot o( plastic Deli3er$ 1ins was (/ll$ 6/sti(ied# The$ were stac&a-le onto each other8 and capa-le o( containing a Gt$picalG '/stomer .rder# 5n those (ew cases in which a 1in was not ade?/ate to contain a (/ll order8 two or e3en ! 1ins wo/ld -e /sed8 all carr$ing the same 5nternal .rder >/m-er stic&ers the comp/terised program was in (act designed in s/ch a wa$ that it wo/ld print as man$ Deli3er$ 1ins Stic&er as necessar$ to cater (or that 3ol/me order# *ll 1ins wo/ld -e placed rationall$ on the Deli3er$ 'o/nter8 (/ll$ read$ (or despatching# o Pac7a'in' o* Cartons o* ;lister Pac7s# ,ith 3er$ similar criteria to those /sed (or the Displa$ 1oxes Pac&aging 'ells8 also a dedicated 'ell (or Pac&aging o( 'artons o( 1lister Pac&s was home-made constr/cted# The operating principle was identical8 with the exception that F/ll Pac&s wo/ld -e inserted into 1listers8 and F/ll 1listers into 'artons# The rationalisation -ro/ght more distinct ad3antages in this case7 the o3erall '$cle Time impro3ed EdecreasedF -$ a whopping 45I# Deli3er$ 1ins containing F/ll 'artons o( 1lister Pac&s wo/ld -e -ro/ght straight awa$ to the Deli3er$ 'o/nter8 exactl$ as in the case o( Displa$ 1oxes# o Pac7a'in' o* Cartons o* 50/200 Sac/ets# ,ith 3er$ similar criteria an *ssem-l$ 'ell Eone onl$F was made also (or this prod/ct8 and dedicated to it# The impro3ement in the o3erall '$cle Time was not as exciting as (or Displa$ 1oxes and 1lister Pac&s - still8 a solid )0I impro3ement was achie3ed and maintained# The main -ene(it was in the rationale o( the processing st$le8 and in the total elimination o( orders mix-/p and misplacements+mis-deli3eries#

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CPA
Created with Visio

Training

o
3e

: 4actory 2ayout# The new 4a$o/t was rather di((erent (rom the pre3io/s one# There is a well demarcated G8oods &ncomin' )reaG8 in which all incoming goods Elocal and ex-importF are temporaril$ par&ed (or necessar$ controls -e(ore -eing placed on their storage areas# The Deli(ery Counter is rationall$ and strategicall$ positioned# The ) Dis"lay ;o es Pac7a'in' Cells8 as well as the ;lister Pac7s Pac7a'in' Cell and Cartons o* Sac/ets Pac7a'in' Cell are strategicall$ positioned close to the shel3es that contain their respecti3e pac&aging materials# This ma&es re(illing o( 'ells; stoc& eas$ and (ast# Shel3ing o3erall 3ol/me has drasticall$ decreased8 d/e to more (re?/ent deli3eries o( local components and d/e mainl$ to the elimination o( the -/l& o( ,5P Ewor& in progressF# The onl$ permanent ,5P is now represented -$ F/ll Sachets8 stored in Shel3ing !# Shel3es ha3e -een rationalised8 not onl$ in position -/t also in si<e# The$ ha3e -een st/died in order to contain the Gpea&G o( stoc& E6/st a(ter recei3ing t$pical deli3eries8 -oth local and ex-importF8 with a margin (actor o( 50I to cater (or a (ew $ears expansion#

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Technical English

CPA
Created with Visio

Training

*ll Shel3es Eexcept Shel3ing 4F are so concei3ed as to allow easil$ the implementation o( the 4&40 E(irst in - (irst o/tF principle o( stoc& rotation Esee also Materials Flow - -elowF# 5n practice8 all Materials Eor Prod/cts; componentsF are now stored directl$ in the processing area or 3er$ next to it Eli&e in the case o( Dr/ms o( Cran/lesF# This minimise an$ handling in3ol3ed8 and rationalises the re-stoc&ing o( processing areas# The wor&ing location o( the two 4a-o/rers is also e3ident# o Materials 4lo:# 5t;s eas$ to see how easier and (aster is stoc&ing o( shel3es in the new la$o/t# The (loor is now (ree and access to the 3ario/s storage areas is (acilitated# %estoc&ing (ollowing the F5F. principles is (acilitated -$ the (ront+-ac& access o( the concerned shel3es# %egaining the ownership o( the (actor$ (loor was one core point in the re-engineering exercise# The simple target was7 Gnothing standing on the (loor8 except (ixt/resG# This -ro/ght a well distinct ad3antage and created an eas$ to mo3e-aro/nd (actor$# o Processin' 4lo:# The o3erall ad3antages can easil$ -e seen in the Processing Flow diagram# Materials mo3ements are minimised7 (rom shel3ing areas the$ can -e -ro/ght to processing areas in a <i((# *lso Finished Prod/cts mo3ements are minimised8 to the extent that it is 6/sti(ied to -ring a Deli3er$ 1in to the Deli3er$ 'o/nter straight awa$ a(ter .rder pac&aging Eto pre3ent an$ possi-le hic&-/p or mix-/pF# The (inal res/lt is a clean8 neat8 organised8 (lowing Factor$8 with 3er$ minimal resid/al waste#

Product Dis"atc/in'# *t collection times E0=700 and 14700F the 'ler&+Pac&aging 4a-o/rer 6/st stops whate3er she is doing and ta&es care o( the deli3er$ process# This is 3er$ simple and streamlined7 the Deli3er$ 'ompan$ dri3er 6/st ta&es the (/ll lot o( Deli3er$ 1ins read$ to -e dispatched and loads them /p in the deli3er$ tr/c&# Each Deli3er$ 1in contains the associated Deli3er$ >ote Ein d/plicateF8 one to -e signed -$ '/stomer and ret/rned a(ter deli3er$# Empt$ Deli3er$ 1ins are ret/rned to the (actor$ a(ter deli3er$# So8 there is alwa$s a lot o( Deli3er$ 1ins G(loatingG -etween Factor$ and '/stomers# The Deli3er$ 'ompan$ is (/ll$ responsi-le (or &eeping the Deli3er$ 1ins in good conditions8 and ret/rning them to the Factor$ once their content is deli3ered# * simple (orm that ta&es care o( assessing the -alance o( Go/t-o(-the-(actor$G Deli3er$ 1ins at an$ moment in time is (illed 6ointl$ -$ the Deli3er$ Dri3er and the 'ler& and signed -$ -oth#

4&3)2 C03S&D!#)5&03S Some (inal considerations on this sol/tion7 Sachets Filling Machines# The alert reader might -e p/<<led -$ the (act that onl$ one machine ended /p -eing /tilised (or sachets (illing# ,ell8 the G-e(oreG s$stem8 (/ll$ Gp/shG and rather disorganised8 relied on large stoc&s o( all components8 incl/ding sachets# The two machines were /tilised (/ll-time8 -/t in a rather chaotic wa$8 and with (re?/ent interr/ptions and disr/ptions Et$pical8 in spite o( excessi3e (illed sachets; stoc&8 was the case o( not ha3ing eno/gh (illed sachets o( a certain (ragrance - and too man$ o( the othersF - disr/ptions were generated -$ the necessit$ o( prod/cing some /rgent stoc& o( the lac&ing (ragrance8 Gchangingo3erG the machine in a h/rr$ to -e read$ (or that (ragrance# .-3io/sl$8 this was 3er$ mess$# 5n the Ga(terG8 -etter organised s$stem8 prod/ction -ecame more -alanced8 easil$ controlled8 and (/ll$ streamlined# The net concl/sion was that one machine was practicall$ s/((icient (or the present needs# Howe3er8 the second machine came hand$ (or se3eral reasons7 maintenance - red/ced cleaning o( hoppers E(or (ragrance changeF - read$ to -e /sed -$ a (/t/re8 !rd wor&er Ein case o( increased salesF - and8 most o( all8 it co/ld -e /sed -$ the 'ler&+Pac&aging 4a-o/rer in her spare time E$es8 she had some spare time8 see -elowF# 5n (act8 than&s to the (lexi-ilit$ and m/lti-(/nction a-ilities o( the 'ler& Eo( the wee&F8 it was possi-le to prod/ce the necessar$ stoc& o( (illed sachets8 and a -it extra Eto -e sa(eF# This (orm/la was (ine (or another 1" months# Then8 d/e to increased sales8 a part-time cas/al la-o/rer was /tilised again at the second machine Ee3ent/all$8 a(ter ! $ears8 a (/ll-time la-o/rer was emplo$ed - with (/nctions+d/ties identical to the other twoF# The mixed s$stem Gp/sh+p/llG had a Gco/pling pointG8 represented -$ the ,5P o( (illed sachets# This was a hand$ compromise# 5t wo/ld ha3e -een (oolish to tr$ to go (or a (/ll Gp/llG s$stem7 this wo/ld ha3e re?/ired sachets (illing+sealing machines8 extra space8 a totall$ di((erent organisation8 and its -ene(its wo/ld ha3e -een 3er$ arg/a-le# S/ch a compromise is normal in man$ GleanG prod/ctions concerns#

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Prod/ction Sched/ling# This res/lted in an extremel$ simple s$stem7 a Gre-stoc&ing+replenishingG method (or prod/ction o( (illed sachets8 and no sched/ling at all (or the (inal pac&aging# The (inal pac&aging was simpl$ Gp/lledG -$ c/stomers; orders# The Ga(terG s$stem was extremel$ responsi3e7 not onl$ the G-e(oreG D<5ime Ec/stomer expected Deli3er$ TimeF was maintained8 -/t it was also impro3ed7 in the case o( 3er$ /rgent orders the 'ler&+Pac&aging 4a-o/rer was a-le to dispatch /rgent orders the same da$ the$ were recei3ed# * ma6or impro3ement8 allowed -$ the new la$o/t Eand8 generall$8 -$ the new s$stemF8 was the 4&40 method o( stoc& rotation# *ltho/gh not 3ital8 as the partic/lar t$pe o( prod/ct had a 3er$ long shel( li(e8 this res/lted in a -etter management and monitoring o( all stoc&s8 with special regard to the stoc& o( gran/les in dr/ms and o( the (illed sachets# The alert reader might also -e p/<<led -$ the (act that one o( the two wor&ers8 the 'ler&+Pac&ager8 had s/((icient time to cope with all her d/ties and tas&s# *t the present rate o( sales8 act/all$ she had ample time8 granted -$ the high prod/cti3it$ associated with the G(low+p/llG s$stem# 1/t8 let;s do some calc/lations7 -She recei3es and process c/stomers orders# This was ta&ing8 at most8 1 hr+da$# -She deals with the Deli3er$ 'ompan$ E085 hr+da$F# -She re(ills all 'ells with components and does some cleaning# %estoc&ing 'ells Edone e3er$ second or third da$F was ta&ing an a3erage o( 15 min/tes+da$ - cleaning and general ho/se&eeping was a max# o( 15 min/tes+da$# *ll together8 a3erage8 085 hr+da$# -'onsidering the hal( ho/r l/nch time8 there are hrs net le(t (or pac&aging Eand sachets (illing8 not e3er$ da$F# ->ow7 at a sales rate o( )#000#000 sachets+$ear8 25I o( which are sold as Displa$ 1oxes8 there are 0825x)#000#000+4+)4 H 15# )5 Displa$ 1oxes to -e pac&aged in a $ear# .3er 11 months Ethe (actor$ sh/ts down (or 1 month e3er$ $earF8 there are 14)0 Displa$ 1oxes to -e pac&aged e3er$ month# 'onsidering )) wor&ing da$s in a month8 this res/lts in an a3erage o( 5 Displa$ 1oxes per da$ to -e pac&aged# *t an e((ecti3e c$cle-time o( ) min/tes per Displa$ 1ox8 this ta&es 6/st a-o3e ) ho/rs8 e3er$ da$# 'onsidering also the time re?/ired (or 'ell preparation Emainl$7 -ringing all la-els and stic&ers and organising the 'ellF - and prod/ct remo3al (rom the 'ell Edestination7 Deli3er$ 'o/nterF - as well as loss o( (oc/s d/e to possi-le c/stomers orders phoned thro/gh while pac&aging - we can conser3ati3el$ sa$ that )85 hrs+da$ are re?/ired to prod/ce the necessar$ 3ol/me o( Displa$ 1oxes# -Since Displa$ 1oxes are the -/l& o( the sales E25IF8 it is eas$ to /nderstand that the 'ler&+Pac&ager has !85 hrs+da$ le(t to pac&age the -alance E)5IF o( the prod/cts8 and to (ill sachets at the )nd machine# This time is m/ch more than eno/gh @@ -.-3io/sl$8 there were GrelaxedG da$s and GhecticG da$s# D/ring GrelaxedG8 eas$ da$s8 the 'ler&+Pac&ager wo/ld prod/ce extra stoc& o( (illed sachets - so that8 d/ring GhecticG da$s8 the other wor&er wo/ld help her with pac&aging tas&s# This was an excellent8 sel(-reg/lated s$stem8 capa-le o( smoothing an$ ripple# -Moreo3er8 there were other sporadic tas&s to -e exec/ted7 (or instance8 recei3ing local materials and imported stoc&8 chec&ing and positioning them on their respecti3e shel3es# .nce again8 the s$stem was Gsel(-reg/latingG7 d/e to the presence o( (illed sachets ,5P8 the second wor&er wo/ld -e a-le to act as a G6o&erG at an$ moment in time# *n$ lost prod/ction o( (illed sachets wo/ld then -e compensated -$ the 'ler&+Pac&ager d/ring Geas$8 relaxedG da$s# Hence the need (or the second Displa$ 1oxes Pac&aging 'ell# This was introd/ced not onl$ to prepare (or (/t/re expansion8 -/t also to allow sim/ltaneo/s pac&aging o( Displa$ 1oxes -$ the two la-o/rers8 sho/ld the Gpea&G come Eand it was coming8 (rom time to time####F @ 5n concl/sion8 the E3er$ smallF in3estment (or the second 'ell was 3er$ well 6/sti(ied# * n/m-er o( initiati3es contri-/ted to the Ga(terG8 astonishing res/lts7 the GFlow+'ell+P/llG st$le - the rationalisation o( the Factor$ 4a$o/t - a re3amped stoc& management and shel3ing s$stem - the o3erall order ta&ing and processing method - the rationalisation o( Prod/ct Deli3er$ thro/gh a Deli3er$ 'o/nter and Deli3er$ 1ins - and8 most o( all8 m/lti-s&ill+m/lti-(/nctional la-o/rers @ :es8 the h/man (actor was the /ltimate winner# The two permanentl$ emplo$ed wor&ers /nderstood Ethro/gh intensi3e8 in(ormal trainingF not onl$ the challenge associated with the new st$le operations -/t also the -ene(its# *nd gra--ed -oth o( them# *nd made things happen# The$ participated intensi3el$ in the re-engineering process8 and came /p with man$ ideas Eto mention 6/st one8 the wireless phone idea came (rom one o( them @F# The$ went into the nitt$-gritt$;s o( re-engineering the entire Factor$ with enth/siasm and deep in3ol3ement8 en6o$ing 3er$ m/ch the switch-o3er process# E3ent/all$8 the$ were extremel$ satis(ied with the new set-/p8 and accepted the challenge e3en (/rther introd/cing more impro3ement details# Their GempowermentG le3el -ecame 3er$ high# E3ent/all$8 the new owner was coming to the Factor$ onl$ sporadicall$8 dedicating his time more and more to mar&eting and promotion# Sales increased steadil$8 also -eca/se prices were &ept stead$ (or long time Eincreased competiti3eness introd/ced -$ increased prod/cti3it$ and lower costsF# Expansion came as expected8 at a -etter rate than expected# ,ithin 185 $ears another wor&er Eone the pre3io/s cas/al la-o/rersF was emplo$ed part-time and a(ter another $ear and a hal( (/ll-time# ,ithin another $ear another o( the pre3io/s cas/al wor&ers was also emplo$ed (/ll-time# ,hich leads to the concl/sion7 a health$ prod/cti3e s$stem generates wealth8 competiti3eness and g/arantees a -etter (/t/re#

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